Apparatus for smelting ores.



J. A. POTTER.

APPARATUS FOR SMELTING 033s.

APPLICATION FILED DEG.23, 1912.

, faitented Oct. 13, 1914.

M m N W a. M I

.L'A. POTTER.

APPARATUS FOR SMBLTING ORB S. APPLICATION FILED DEG.23, 1912.

Patented 0@1;.13,1911- 3 SHEETSSHEET 2.

J. A. POTTER. APPARATUS FOR SMELTING ORES. APPLIOATION FILED DEO.23,1912.

1,1 13,481. Patented 0013.13, 1914.

3 SHEETS-SHEET 3.

Fla .7

INVENTOR WITNESSES a. 74% BY M I d-W com: A. roman-or runnno, COLORADO. I

.- APPARATUS FOR SHEL'IING: ORES.

Specification. a: Letters IPatent. application fllcd'December 23, 1912. Serial 30.738345.

' Patented Oct. 13, 1914.

To all whom it may concern:

.Be it known that-I, JOHN A. Fo rrna, a citizen of the United States, residing at Pueblo, in the county of Pueblo :and State provide an-improved of Colorado, have invented new and useful Improvements in Apparatus for Smeltmg Ores, of which the following is a. specification.

llhe object ofthepresent invention. is to apparatusfor separating metals such as gold, silver, 11011, copper, leach-zinc, antimony and bismuth from-ores, drosses, mixtures, .mattes, slags, and the like. In the accompanying drawing, Figure 1 is a plan view 'of my improved apparatus,

'certain parts being broken away; Fig. 2 1s a broken longitudinal vertical section on the line 2-'2 of Fig. 1; Fig. 3 is a vertical cross section on the line 33 of Fig. 1; Fig. 4' is ed steel columns strengthened and.

' said chamber 6 is a vertical cross section on the line 4-4'-'of Fig. 2.

Referring to the drawings, 1 indicates concrete foundations, on which are support 2, and fire brick walls 3, bound together by plates 4 and brace st-aves 5, which bind together the walls of the gas-producing chamber 6 and fusion chamber 7.

8 indicates an ore shaft, and 9, 9 condensing regenerating flues, the rear ends of which communicate with an air supply pipe 12 controlled by a Valve 10, and leading upwardly from a blast pipe 24 and also communicating with an upwardly leading exhaust pipe 12, said communications being controlled by a butterfly valve 11.

13 indicates an inclined plate located at the bottom of the ore shaft 8, on which plate is made to move a ram 14 and on .which plate are secured shaft bearings 15 and 15, in which bearings is a shaft 16 having secured thereon a sprocket wheel 21 and cams 17 and 17 that revolve inside eccentrics 18 and 18, connecting with lugs 19 and 19' of the ram 14 by a shaft 20. Connected to the lower end of the gasproducing chamber 6 is a. pipe 22 controlled by a valve 23 and leading from the blast pipe 24. An oil or gas pipe 25 connects with the chamber 6 above the air pipe 22, and in the upper portion of the rear wallin an opening 26 covered by a door 26. At the bottom of the sides of the chamber 6 are'clearing doors 45, 45'.

The condensing and regenerating flues 9 'metal spout and 38, 38

1 ment of ore mixture 42. Now,

and. 9 :open into the fusion chamber 7 by ports-.27 and 27. The regenerating flues contain a longitudinal series of bafllin walls; 28, 28, and in the lower portions 0 saidvflues are a series of basins 29, 29 having spouts 30 and tap holes 30.

31,31 indicate ladles suspended by harness from carriages 32, 32 running on rails 33, 33'.

34' indicates an ore-charging car, running on rails-35, 35'.

-36 indicates a furnace door, 37 a slag and inwardlv flaring holes for the insertion of a bar through the furnace wall.

39.and 39 indicate oil or gas pipes, 40 and 40platforms, and 41, a furnace door lever.

'42 indicates the ore mixture embankment,

43 asheave wheel on the butterfly valve 11,'

and 44 a hand rope over wheel; while 46 indicates the twyer holes connecting the chambers 6 and 7.

47 indicates the liquid metal, 48 the slag tap hole and 48 the metal tap hole below the slag hole 48, 49 the settling ladle, and 50 the slag floating on the liquid matte or metal" in the chamber 7.

The ores or mate-rials to be treated may contain one or more metals, or carbonates or oxids of metals in combinations comprising gold, silver, iron, cop-per, lead, zinc, antimony, bismuth and the like.

he treated contains oxid of iron, copper, lead and. zinc with .a-small percentage of sulfur,

which ores are crushed and mixed with fluxes, to about corn size or smaller. These are fed into the shaft 8, and fall on to the plate 13. The"charging operation is continued until the stack 8- is full, at which time a portion of the charge has passed forward over the twyer holes 46 into the melting chamber 7, there forming the embankat this time, fire is started in the chambers 7 and 6 by first admitting air under pressure through the valve 10 and butterfly valve 11 into and through the condensing and regenerator flue 9, down through the port 27, where oil or gas, flowing from the pipe 39, is encountered, and where ignition, combustion, and heated gas are produced, which fills the chamber 7 and passes therethrough around the face of the ore 42, into and. up the port 27, into and through the condensing and As an ex-' ample, we w1ll suppose that the material to regenerating flue 9, into and through the butterfly valve 11,into the pipe 12, whence it is conveyed for further treatment. N ow after about one hours time the courseof air, fuel and gas currents are reversed, by pulling down on the hand rope 44, causing the wheel 43 and butterfly valve 11 to rotate about one-fourth of a revolution, thus causing the air blast to pass into and through the condensing flue 9, down and into the port 27 where it encounters oil or gas which instead of flowing through the pipe 39 has been caused to flow through the pipe 39', where ignition and combustion, now take place and the resulting gas travels through the chamber 7 through the port 27, and into and through the condensing and regenerating flue 9, into and through the valve 11 and pipe 12, as before stated, for further treatment. Now while these reversals are proceeding intermittently, fire is also started in the gas-profusion of earths,

ducing chamber 6, by admitting into said chamber air through the valve 23, when it encounters oil or gas flowing through the pipe 25, whereupon ignition and combustion are produced, the resulting gases passing through the twyer holes 46 into and through the ore 42 and into the chamber 7, there associating and moving with the heretofore described gas currents passing through said chamber 7.

Now after all the parts have reached the proper heat conditions for operations, the

. temperatures and the characters of the gases produced are regulated by adjusting the air and fuel supply so as to produce and maintain a hot reducing gas in chamber 6 of about 2000 F. which gas at such a temperature and under suflicient pressure permeates and commingles with the crushed ore mixture 12, there combusting the oxygen associatcd with the ore mixture, thereby forming metallic particles of zinc, lead, copper, iron, and matte. The zinc particles when formed immediately become volatilized and pass into chamber 7 with the reducing gas curr=nts, while the iron, copper, lead and the like form matte particles that begin to liquate and precipitate to the bottom of the'chamber 7, and accumulate at the point 47, under the liquid slag formed by the fluxes, and the like. Now

while these actions are proceeding, fluid fuel and air are supplied in such proportions by the conduit 39 or 39, and flue 9 or 9' that highly heated reducing gas is being produced under suflicient 27', as the case may be, that penetrates, fuses and liquefies the exposed faces of the deoxidized ore embankment 42, forming thereblanket, that fuses from the the chamber bottom, while particles of lead, copper, or

on a liquid slag ore faces onto setting free the 5 iron matte, that in turn liquate and prepressure at port 27 or cipitate on to the furnace hearth under the liquid slag according to their specific gravity, while the fusing hot gas also associates with the reducing gas containing the zinc vapor issuing from the ore faces, thus protecting them from oxidation, and the combining gas currents then pass out of the chamber 7 under pressure into port 27 or 27, up into condensing flue 9 or S), where they encounter baffling walls 28' or 2S, and there give up the zinc vapor, which condenses, falls and accumulates in a liquid state in the basins 29 or 29. Finally the. cooled, shrunk, monoxid gas passes through the valve 11 intothe pipe 12, whence it is conveyed for further treatment and uses, as it still contains metallic and calorific values.

Now as the above outlined actions are proceeding, the ore embankment is being renewed as fast as its faces are fused away, since the ram 14 is caused to move forward and backward on the plate 13 by mechanical power applied to the wheel 21, shaft 16, cams 17 and 17 eccentrics 18 and 18, shaft 20, to lugs 19 and 19, of the ram 14, thus causing the descending ore mixtures to be and through crowded forward over the twyer holes 46" into the chamben 7, while at the same time new ore mixtures are being fed into the top of the ore shaft 8.

While the above operations are proceeding, the newly formed unvaporized metals and mattes are being liquated and precipitated; the lead to the bottom of the chamber, while the copper floats on the lead, and the matte in turn floats on the copper, and the slags float on the matte at the point 47, whence they are withdrawn at intervals through the tap holes 48 and 48 and spout 37 into the ladle 49 and thence removed as desired. In the meantime, the condensed zinc vapors have been accumulating in the basins 29 or 29, from which they are Withdrawn alternatel just prior to the reversals of the air, fuel and gas currents. Hence it will be seen that a continuous process is obtained. I

Should it be desired to extract volatilizable metal or metals from metallic mixtures, ores, and the like by volatilization and condensation only, and not to fuse to a liqu1d the ore mixture, operations are carried on the same as above with certain exceptions. Less heat is maintained in the chamber 7, thereby sintering the ore mixture only, thus necessitating its removal from the chamber 7 by hand rakes through the door 36, during which time all heat operatlons cease and about two-thirds of the ore'embankment 1s withdrawn, after which the door 36 is closed and operations resumed.

Carbon or hydrocarbons may be mixed with ore mixture as coal, coke, peat, wood, asphaltum, and the like, in finely divided state, which mixture is gasified by the heat dust or. powder of the obtained from the combustionof fuel and air in the chamber7, while the gases generated from the charring mixture'of hydrobo i nd. O ns met ore mixture, reduce, the metals, and volatilize, carry and proteet them from oxidation, while they as obiate themselves with the ases passing through the ore explained. a In thisease, the deoxidized ore mixture can be conyerted into ajSlag,

.setting free any non-volatilizablemetals .as

before outlined, or it can be withdrawn from the chamber 7 infa smtered state, and it First, instead of a reducing gas being main: tained in the chamber 7 an oxidizing atmos phere is produced, thereby oxidizing the metal vapors and gasissuing from the faces of ore embankment 4 2, thus forming an oxid volatili zed metals, that, with the burnt gas, travels through and out of the chamber 7 into the ports 27 and 27., into the regenerating fives 9 or 9, from hilethe gasify which the bafiling'walls may have been re- 'oxid' of .iron to wrought ores containing iron alone, or associated from the chamber moved to, give free passage to the cooling gasesand oxid dusts, which 'finally pass into the pipe. 12 and are then conveyed to a filtering department, as a bag house, or the like, where the oxid dusts are obtained.

It is-understood that the, above process i conducted either continually or intermittently, as when melting the ore mixture into a liquid, or where it is withdrawn from furnace in a sintered state, bon; or hydrocarbonaceous mixture or reducing; gas can be utilized for deoxidizing agents in the oreembankment. 42. When employing this arrangement for reducing orcast iron from with one or more volatilizing metals, the process is carried on about 'as in the first case, with the following differences. When making wrought iron,

fluxes and limited amounts of carbonaceous materials charged and deoxidized with gas 6. At the same time a highly heated reducing atmosphere is maintained under a suitable pressure in chambers 6 and 7, when the fluxes and earths from slag that becom liquid and liquate from face of the ore embankment 4=2 on to the furnace hearth 50, leaving the reduced wrought iron particles on the face of ore embankment, which in a short time form a crust of' wrought iron of honey-comb e' oxygen in the the holes38 and chamber 7 as fl',

dmitted' .c i nx d i n O pass if with and that a carthe ore is mixed withformation, When this crust becomesabout 2 inches thick the gas pressure and currents are reducedincha bersfti and 7, and workmen insert hooked bars into and through 38' into' the chamber 7 and proceed to peel off the crust of wrought iron from the ore embankment and form same into balls by pressing it against the side walls of the furnace, thus welding the metal togetherinto ballsof about 20 inches in diameter, which are then withdrawn from the chamber 7 through the door 36 and further'treated asdesired. A Now this peeling and ballingjis intermittent, and requires about 20 minutes for each peeling, balling and extracting, after which time the process is renewed, and a new crust is formed in about 30 minutes time, while feeding the ore and tapping slag isproceeding. Should the ore mixtures contain volatilizable metals, they the gas into condensing flue 9 or 9, and are recovered, as before explained.

Toproduce cast iron the process is carried onsimilarly to that when making wrought iron, exceptthat excess carbon or hydro-carbonaceous materials are mixed with the ores, and air, cold or pre-heated, is blown into the chamber 6, then through the twyer slot 46, there permeating and combusting the'fuel mixturejin ore embankment; thus deoxidizing the ore, also carbonizing the recovered metals while melting, which then precipitateion to the hearth under the slag which is then forming, whence they are intermittently withdrawn and dispensed with as desired. I have employed this method to convert steel and wrought 'ron clippings, borings, turnings and the like into cast iron, by mixing carbonaceous materials with the metals and melting' 'the mixturewith flame from the port 27 or 27, thus melting the faces of embankment away and bringing the metal particles into close contact with the incandescent carbon and the reducing gases.

whereby carbon is then absorbed. I may add that, by this same treatment, cast iron, as pig, scrap. borings, turnings, and the like, have been successfully melted and their metaloids,as carbon, silicon, manganese, and the like, preserved while melting, thus opening up a new field in general foundry work, as melting by oil or gas is cheaper and quicker than with coke.

Coal can be gasified in the chamber 6 and a coal fired furnace could be used to furnish a fusing flame, and a stack can be added, but I find that'to combust the fuel, an undersufiicient pressure is far more effective and economical, as then the reducing gas maintained in theme body and chambers 6 and 7 and regenerator fines promote better conditions .to deoxidize, volatilize, and protect the metals from oxi-- means for connecting condensing metallic vapors,

1. In an apparatus of the character de-:

scribed, the combination of a furnace having a rear wall, through a central opening in which ore to be treated is charged, condensing and regenerating flues opening through 'said rear wall on opposite sides of said central charging opening, an exhaust conduit, a pipe for conducting. air under pressure, either of said fiues With said pipe, and theother with said exhaust conduit, and means in said flues for and for separating from said flues the liquefied metal resulting from the condensation of said vapor.

2. In an apparatus of the character described, the combination of a furnace having a rear wall, through a central opening in which ore to be treated is charged, condensing and regenerating flues opening through said rear wall on opposite sides of said central charging opening, conduits for fluid fuel discharging adjacent to the openings of said flues into said furnace, an exhaust conduit, a pipe for conducting air under pres: sure, means for connecting either of said flues with said pipe, and the other With said exhaust conduit, and means in said flues for condensing metallic vapors, and for separating from said flues the liquefied metal resulting from the condensation of said vapor.-

In an apparatus of the character described, the combination of a furnace having a rear wall, through a central opening in which ore to be wall being formed immediately beneath said charging opening with a small opening for permitting the passage of a gas to said furnace through the body of ore charged thereinto from said charging opening, an exhaust conduit, a pipe for conducting air under pressure, means for connecting either of said flues with said pipe, and the other with said exhaust conduit. and means in said flues for ing from condensing metallic vapors, treated is charged, said rear condensing metallic vapors and for separatsaid flues the liquefied metal result mg from the condensation of said vapor.

4- In an apparatus of the character de scribed, the combination of a furnace having a rear wall, through a central opening in which ore to be treated is charged, said rear wall being formed immediately beneath said charging opening with a small opening for permitting the passage of a gas to said furnace through the body of ore charged thereinto from said charging opening, and said apparatus having a gas producer chamber connected with said small opening, an exhaust conduit, a pipe for conducting air under pressure, means for connecting either of said flues with said pipe, and the other with said exhaust conduit, and means in said flues for condensing metallic Vapors and for separating from said flues the liquefied metal resulting from the condensation of said vapor. I

5. In an apparatus of the character described, the combination of a furnace having a rear Wall, through a central opening in which ore to be treated is charged, said rear wall being formed immediately beneath said charging opening with a small opening for permitting the passage of a gas to said furnace through the body of ore charged there- 1 into from said charging opening, and said apparatus having a gas producer chamber connected with said small opening, means for supplying fluid fuel to said gas producing chamber, and means for supplying a blast of air thereto, an exhaust condult, a pipe for conducting air under pressure, means for connecting either of said flues with said ipe, and the other with said exhaust condhit, and means in sald flues for Y and for separating from said flues the liquefied metal resulting from the condensation of said Vapor.

In testimony whereof I have hereunto set my hand in the presence of two subscrlbmg witnesses.

JOHN A, POTTER.

Witnesses:

W. W, BoUoH'roN, JonL T. TRAYLOR. 

